torque SUBARU FORESTER 2004 Service User Guide
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 38 of 2870
AC-36
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Compressor
11.Compressor
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.3 — 0.6 mm (0.0118 — 0.0236 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
No. 3 terminal of the compressor connector.
3) Make sure the magnet clutch engages.
If NG, replace the compressor.
B: REMOVAL
1) Perform the compressor oil return operation.
2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge
refrigerant.
4) Disconnect the ground cable from battery.
5) Remove the V-belt.
6) Remove the generator.
7) Remove the low-pressure hose and high-pres-
sure hose.
8) Disconnect the compressor harness from body
harness.9) Remove the bolts to remove compressor brack-
et.
10) Remove the bolts and then separate compres-
sor and bracket.
C: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hos-
es with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil.
4) Charge refrigerant.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
AC-00048
AC-00049
AC-00336
AC-00051
Page 39 of 2870
AC-37
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Condenser
12.Condenser
A: REMOVAL
1) Using the refrigerant recovery system, discharge
refrigerant.
2) Disconnect the ground cable from battery.
3) Disconnect the pressure hose and pipe from
condenser.
4) Remove the radiator bracket (A).
5) Remove the two bolts. While lifting the condens-
er, pull it out through the space between radiator
and radiator panel.
CAUTION:
Be careful not to damage the radiator fins and
condenser fins. If a damaged fin is found, repair
it using a thin screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil to the compressor.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Replace the O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser has been fitted
into holes on radiator panel.
2) Charge refrigerant.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
tion.>
C: INSPECTION
1) Check that no dust or insects are found on the
condenser fins. Air-blow or flush fins with water as
needed.
2) Check that no oil leaks from condenser. If a fail-
ure is found, replace the condenser with a new one.
AC-00246
AC-00053(A)
AC-00091
AC-00092
Page 41 of 2870
AC-39
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Heater Cooling Unit
14.Heater Cooling Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, dis-
charge refrigerant.
3) Drain the engine coolant from radiator.
4) Remove the bolt securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
5) Remove the instrument panel.
6) Remove the support beam.
7) Remove the blower motor unit assembly.
bly.>
8) Disconnect the servo motor connectors.
9) Remove the bolt and nuts to remove the heater
and cooling unit.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Charge refrigerant.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
AC-00870
AC-00055
Page 43 of 2870
AC-41
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Hose and Tube
16.Hose and Tube
A: REMOVAL
CAUTION:
When disconnecting/connecting hoses, do not
apply excessive force to them. Confirm that no
torsion and excessive tension exists after install-
ing.
Seal the disconnected hose with a plug or vi-
nyl tape to prevent foreign matters from enter-
ing.
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, dis-
charge refrigerant.
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
5) Disconnect the low-pressure hose from evapo-
rator unit.
6) Disconnect the low-pressure hose from com-
pressor.
7) Remove the low-pressure hose from vehicle.
8) Remove the high-pressure hose attaching bolts
(C).
9) Disconnect the high-pressure hose from com-
pressor.
10) Disconnect the high-pressure hose from con-
denser.
11) Remove the high-pressure hose from vehicle.
12) Remove the high-pressure tube attaching bolt
(D).
13) Remove the high-pressure tube from vehicle.
B: INSTALLATION
CAUTION:
When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension exists af-
ter installing.
Seal the disconnected hose with a plug or vi-
nyl tape to prevent foreign matters from enter-
ing.
Replace the o-rings for hoses and pipes with
new ones, and then apply compressor oil.
1) Install in the reverse order of removal.
2) Charge refrigerant.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
C: INSPECTION
NOTE:
Check the hoses for cracks, damage and expan-
sion. If any failure is found, replace them with new
ones.
AC-00869
(A)
(C) (B)
(D)
Page 102 of 2870
AB-2
AIRBAG SYSTEM
General Description
1. General Description
A: COMPONENT
1. SRS AIRBAG
(1) Combination switch ASSY with roll
connector(5) Airbag control moduleTightening torque: N·m (kgf-m, ft-lb)
(6) Side airbag sensorT1: 5.9 (0.59, 4.4)
(2)
TORX
® bolt T30(7) Wiring harness rear
T2: 7.4 (0.75, 5.4)
(3) Airbag module ASSY (Driver’s
side)(8) Side airbag moduleT3: 10 (1.0, 7.2)
(9) Wiring harness CTRT4: 20 (2.0, 14.5)
(4) Airbag module ASSY (Passen-
ger’s side)(10) Wiring harness frontT5: 25 (2.5, 18.1)
(11) Front sub sensor
AB-00685
T3
T2
T5
T3
T4(2)(4)
(3) (1)
(2)
(10)
(11)
(9)
(7)(6) (5)
(8)T2
T1
Page 114 of 2870
AB-14
AIRBAG SYSTEM
Driver’s Airbag Module
4. Driver’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
1) Position the front wheels straight ahead. (After
moving the vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure that
the vehicle moves straight ahead).
2) Turn the ignition switch to OFF.
3) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
4) Using the TORX
® BIT T30, remove the two
TORX® bolts on side of steering wheel.
5) Disconnect the airbag connector on the back of
airbag module, and then remove the airbag mod-
ule.
6) Refer to “CAUTION” for handling of removed air-
bag module.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
Check for the following, and replace damaged
parts with new ones.
Airbag module, harness, connector, and mounting
bracket are damaged.
cations After a Collision.>
(1)
TORX® BIT T30
CC-00018
(1)
AB-00033
Page 115 of 2870
AB-15
AIRBAG SYSTEM
Passenger’s Airbag Module
5. Passenger’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the glove box.
4) Detach the airbag connector from support beam
bracket, and then disconnect the airbag connector.
5) Remove the three bolts, and then carefully re-
move the airbag module.
6) Refer to “CAUTION” for handling of removed air-
bag module.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
Check for the following, and replace damaged
parts with new ones.
Airbag module, harness, connector, and mounting
bracket are damaged.
tion Locations After a Collision.>
AB-00117
Page 116 of 2870
AB-16
AIRBAG SYSTEM
Side Airbag Module
6. Side Airbag Module
A: REMOVAL
CAUTION:
Before working on the airbag module, refer to
the “CAUTION” in General Description.
NOTE:
Remove the passenger’s side by referring to driv-
er’s side.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the front seat from the vehicle.
4) Remove the clip from slide rail IN (A) and re-
verse side of seat cushion assembly, and then re-
move the side airbag harness.
5) Remove the backrest cover.
6) Remove the side airbag harness from backrest
frame assembly.7) Remove the side airbag module (A) from back-
rest frame assembly.
B: INSTALLATION
1) Ensure there are no foreign particles on side air-
bag module.
2) Install the side airbag module (A) to backrest
frame assembly.
Tightening torque:
5.9 N·m (0.59 kgf-m, 4.4 ft-lb)
AB-00474
(A)
AB-00475
AB-00476
(A)
AB-00477
(A)
Page 118 of 2870
AB-18
AIRBAG SYSTEM
Airbag Control Module
7. Airbag Control Module
A: REMOVAL
CAUTION:
Do not disassemble the airbag control mod-
ule.
If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new part.
Do not drop the airbag control module.
After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the console cover.
4) Remove the center console panel.
5) Disconnect the connector from airbag control
module.
6) Remove the four bolts, and then remove the air-
bag control module.
B: INSTALLATION
CAUTION:
Use new bolts (for airbag control module only)
during reassembly.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
Check for the following, and replace damaged
parts with new ones.
Control module, connector, and mounting brack-
et are damaged.
Airbag is deployed.
Side airbag is deployed.
AB-00035
Page 119 of 2870
AB-19
AIRBAG SYSTEM
Side Airbag Sensor
8. Side Airbag Sensor
A: REMOVAL
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the outer belt (FRONT).
Belt.>
4) Detach the side airbag sensor, and then discon-
nect the airbag connector.
B: INSTALLATION
CAUTION:
Use new TORX® bolts T30 when reassembling.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
Check for the following, and replace damaged
parts with new parts.
Bracket connector for side airbag sensor is dam-
aged.
Side airbag is deployed.
AB-00036